1. Applying the 5 Whys Lean Problem Solving DPZIETLOW & ASSOCIATES www.strategicleanorg.com

2. Problem Solving Basic Problem Solving Tools – 5 Whys – Pareto Chart – Cause and Effect Diagram Advanced Statistical Tools – Hypothesis Testing – Design of Experiments – Response Surface Mapping DPZIETLOW & ASSOCIATES www.strategicleanorg.com

3. 5 Whys – Ask “WHY?” at least 5 times to get to the root cause “Because we’ve always done it that way” is NOT a root cause DPZIETLOW & ASSOCIATES www.strategicleanorg.com Turn it into an opportunity

4. 5 Why Application DPZIETLOW & ASSOCIATES www.strategicleanorg.com The fuse blew The motor overheated The shaft was misaligned Θ 1 st Why 2nd Why 3rd Why

5. 5 Why Application Continued Θ DPZIETLOW & ASSOCIATES www.strategicleanorg.com The shaft bearing was damaged The shaft seal was missing 3rd Why 4 th Why 5th Why

6. Mistake Proofing Ingenious devices to prevent the processing of discrepancies (data, information, parts or materials) by the use of gauges, gates, deflectors, sensors, limit switches, etc. In such a way that only acceptable results will be allowed to proceed to the next downstream operation Examples  DPZIETLOW & ASSOCIATES www.strategicleanorg.com

7. Mistake Proofing in Cars Can’t start the car unless it’s in park or clutched Can’t fit a diesel nozzle in the gas tank Doors lock when speed is greater than 5 mph Bell chimes when head- lights left on Headlight s automatic ally burn & extinguish Bell chimes when seatbelt not worn Indicator lights when fuel is low Gas cap is attached to car by a lanyard Oil & fuel specs are listed on caps or tanks Bell chimes when turn signal left on Light indicates that parking brake is engaged DPZIETLOW & ASSOCIATES www.strategicleanorg.com